Method of packaging food articles



Feb. 11, 1969 R. E. PAIGE METHOD OF PACKAGING FOOD ARTICLES Sheet Filed Feb. 18, 1965 R m N E M Ric/lard f. Paigg BY W ATTDRN .5.

Feb. 11, 1969 R E. PAIGE 3,426,499

METHOD OF PACKAGING FOOD ARTICLES Filed Feb. 18, 1965 Sheet 2 of 4 ealn verticalseam mdenfside elm w [s of Zqbe 7 nd cuz glee rel Low arms flea/ma, jf/ed b guz fldvence we and Fansverse/y sea filled sealed box; Zop a new box an boZZa/n and formed aver barf of Zue l INVENTOR W Richard 5. Page ATTDR'NE 5.

R. E. PAIGE Feb. 11, 1969 METHOD OP PACKAGING FOOD ARTICLES Sheet Filed Feb. 18, 1965 INVENTOR Richard Page R. E. PAIGE Feb.11,l969

Sheet Filed Feb.

INVENTOR Pic/rare! Z5 Pazlge 5 a W W A 1 z w m 1 W M 5 l 7 z. A z :5 5% fm a M m 3 m w 4 y 2 ,2 H s m T i; J, LR a w an Claim ABSTRACT OF THE DISCLOSURE Apparatus for and method of continuously forming, filling, sealing and separating small folded up boxes containing various articles. Thin paper coated on both sides in the form of a web is fed continuously from a roll and is used to be wrapped continuously around an axially, vertically extending rectangular inner guide tube by a similarly shaped outer tubular paper funnel and pulled down around and around the inner guide tube to form a rectangular shaped paper tube. Opposite overlapped edges of the paper tube are pressed together by a hot sealing bar to form a continuous fused seam extending longitudinally along the paper tube. Periodically, a pair of opposed fingers bend inwardly at first two opposite small sides of the paper tube and then a pair of opposed hot jaws squeeze the other two wide sides of the paper tube together to form a fused transverse seamed closure at the bottom of the paper tube and to close a preceding filled box.

This invention relates to an apparatus for and method of continuously forming, filling, sealing and separating small folded up boxes containing various articles, the boxes being filled with fluent contents and to the construction of such boxes.

Heretofore, folded up boxes which have been used for containing articles such as small candies having diiferent shapes and sizes of balls and lumps have been manufactured individually by diecutting sheet material to form a blank, and glueing edges of the blanks together to produce knocked down boxes in flattened form. Then, these fiattened boxes have been shipped to a place of assembly and use, then set up one at a time, lined with wax paper and filled with candy. The closure flaps of the boxes are then tucked in to close the filled boxes. If the boxes are to carry printing, the printing is applied to the sheet material prior to diecutting. For this method of packaging, many proc' ess steps are required and much work is involved. Many expensive printing plates, dies, and difierent types of machines are required. Also, the sheet material used is a rather costly heavy gauge box board ranging in thickness from twelve to eighteen thousandths of an inch or more.

In prior Patents Nos. 3,006,121 and 3,082,583, there are disclosed methods of continuously making paper boxes and filling the same with liquid such as milk or cream. To carry out these methods, a continuous paper web is used which has been preformed by creasing, scoring or embossing. In the method of Patent No. 3,082,583, cuts are made in addition in the web and excess waste parts are removed prior to winding into a roll. In order to practice the methods of both patents very complex, expensive precision apparatus is necessary so that preformed creases, notches, tabs and cuts register precisely with operating parts of the assembly apparatus.

In Patent No. 3,006,121, the complex apparatus includes a plurality of conveyor belts, a multiplicity of heat-' ing and pressing die assemblies carried on conveyor chains, multiple rollers for shaping the paper web and other complicated component parts.

The present invention avoids the complex assembly and filling apparatus of the prior packaging and does not require precreasing, prescoring, embossing or precutting United States Patent ice of paper webs and wastage of web material prior to assembly of the boxes.

Instead of using heavy folding box board, a relatively thin paper having a thickness of about five or six thousandths of an inch is used. The paper is thinly coated on both sides with a transparent thermoplastic material such as polyethylene. This material is moistureproof and greaseproof. The paper web is fed continuously from a roll and is caused to be wrapped continuously around an axially, vertically extending rectangular inner guide tube or funnel by a similarly shaped outer tubular paper funnel and pulled down and around the inner guide tube to form a rectangular-shaped paper tube. The outer funnel has a width at its upper end approximately the width of the paper and is so formed that it terminates at its lower end in rectangular shape. Overlapped opposite edges of the paper tube are pressed together by a hot sealing bar to form a continuous fused seam extending longitudinally along the paper tube. Periodically, a pair of opposed fingers bend inwardly at first two opposite small sides of the rectangular-shaped paper tube and then a pair of opposed hot jaws sequeeze the other two wide sides of the paper tube together to form a fused transverse sea-med closure at the bottom of the paper tube and to close a preceding filled box. After the transverse seam is formed, fluent material is dropped through the rectangular inner guide tube or funnel into the seamed rectangular paper tube. The fluent material may be a liquid, a granular material, or small articles, such as candies in various suitable shapes and sizes. After a certain quantity of fluent contents have been discharged through the guide tube, the paper tube is advanced downwardly a predetermined distance by the downward movement of the hot jaws themselves while effecting the transverse fusing operation. Thereafter, the fingers again bend inwardly the opposite first small sides of the paper tube and the hot jaws advance to form the transverse sea-m. A filled box is thus formed. The paper tube to which the filled box is attached then advances to a cutting station where the transverse seam is severed to free the filled box Which now has been closed by two transverse seams, one at each opposite end. This invention thus makes possible for the first time, a method of simultaneously forming, filling, sealing and separating of fiat, rectangular boxes by relatively simple apparatus. The boxes can be packed compactly in shipping cartons for shipment and display. They can be stacked neatly in piles at point of sale or they can be hung neatly on racks in orderly rows for effective display and merchandising.

It is therefore, the principal object of the invention to provide a novel simplified method of making and filling boxes with fluent material from an uncreased and uncut roll of thin plastic coated paper.

Another object is to provide a packaging method and apparatus in which a thin web made of foldable paper coated with thermoplastic material is folded to form a rectangular tube fused at overlapped edges to form a continuous longitudinal seam, fused transversely at predetermined spaced intervals to provide top and bottom clos- -ures, each box being filled with fluent material or articles between the time of forming one end seam of the box and the other end seam of the box, and the transverse seams being severed in turn to free each filled box from the rectangular tube.

A further object is to provide a packaging method and apparatus in which a web of a foldahle paper coated with thermoplastic material is continuously guided by an outer funnel and folded around a combined rectangular inner guide and filler tube to form a rectangular paper tube, overlapped edges of the paper tube are fiused by a heated plate to form a continuous longitudinal seam,

transverse seams are made in the paper tube by applied heated jaws at predetermined spaced intervals to form boxes, with fluent material or articles being passed through the inner guide tube into the rectangular paper tube to fill each box in turn before the box is sealed closed, the filled box then being separated from the paper tube by a cutting blade severing the transverse seam connecting the box to the paper tube.

For further comprehension of the invention, and of the fiurther objects and advantages thereof, reference will be had to the following description and accompanying dra'wings, and to the appended claim in which the various novel features of the invention are more particularly set forth.

In the accompanying drawings forming a material part of this disclosure:

FIGURE 1 is a fragmentary prespective view of the apparatus at one stage of its operating cycle used in carryin-g out the steps of the present process of forming and filling boxes.

FIG. 2 is a cross-sectitonal view of the forming tubes or funnels on an enlarged scale taken on line 2--2 of FIG. 1 and showing how the hot vertical seal bar is applied to the overlapped edges of the paper tube.

FIG. 3 is an enlarged cross-sectional view on a further enlarged scale taken on line 3-3 of FIG. 1 showing parts at a stage of operation during the transverse seam forming step.

FIG. 4 is an enlarged fragmentary vertical sectional view taken on line 44 of FIG. 1, showing parts at another stage in the transverse seam forming step.

FIG. 5 is a front elevational view of a box formed by the apparatus of FIGS. 1-4.

FIG. 6 is an enlarged top plan view of the box of FIG. 5, parts being broken away.

FIG. 7 is an enlarged cross-sectional view taken on line 77 of FIG. 5.

FIG. 8 is a side elevational view of the box of FIG. 5.

FIG. 9 is a flow diagram in block form setting forth the operational steps of the packaging cycle.

FIG. 10 is a front elevational view of another box which can be formed by modification of the packaging cycle.

FIG. 11 is an enlarged top of the box of FIG. 11.

FIG. 12 is a side elevational view of the box of FIG. 10, and

FIG. 13 is a reduced fragmentary, perspective view of the box of FIGS. 10-12.

Referring first to FIGS. 1-4, there is shown apparatus 20 including a stationary, vertically extending rectangularly-shaped inner tube or tunnel 22 forming and filling and carried by support 22a. This tube or funnel may have a hopper at its upper end into which fluent material such as pieces of candy or other small articles A can be poured. Spaced from and encircling an intermediate portion of tube '22 is an outer long paper forming tube or funnel 24. This funnel 24 is rectangular at its lower end 25 and tubular in form. The tubular end of this outer tube terminates slightly above the bottom open end of inner tube 22. The upper end 26 of the outer tube or funnel 24 is opened and flattened with curled opposing edges 27a, 27b to receive a flat plastic coated paper web W comprising a paper body B coated on opposite sides with transparent plastic layers L1, L2. The [upper end of the funnel tapers downwardly to rectangular term and edges 27a, 27b cross each other and overlap in a scroll-like formation S to guide web W down and around the tube or filling funnel 22 so as to shape or form the web into a rectangular paper tube T, open at the bottom and top. The outer funnel is carried by a stationary support 29. A long slot 30 is out out of a corner of the lower end of the outer funnel 24 to expose a longitudinal marginal edge portion E1 of the paper tube.

The web W is taken from a roll I. carried on a rotatable shaft 34 supported on suitable brackets (not shown). The web W is pulled over a stationary rod 35.

A heated die head or sealing bar 50 which is operable between heat sealing and retracted positions by any suitable means, supports a fiat vertical die plate 54 which is aligned with slot 30 in outer funnel 24 to press overlapping vertical marginal edge E1 of the paper tube T against adjacent edge E2 of the tube T to effect a fused vertical, longitudinal seal SL1, FIG. 2.

Located in a plane immediately below the open bottom end of tube .22 are two opposing die fingers 56a, 56b which are operated together between working and retracted positions by any suitable means, such as solenoids. These die fingers are axially aligned with the opposite narrow edges W3, W4 of paper tube T and the central medial plane of inner tube or funnel 22 parallel to walls 33a, 33b of the outer funnel 24 and adjacent walls 21a 21b of the inner tube 22. These fingers can be cyclically advanced to fold in opposing portions of the narrow slides W3, W4 of tube T in the manner best illustrated in FIG. 3.

Movably disposed at opposite wider sides W1, W2 of paper tube T just below the lower end of inner tube 22 near walls 21a, 21b are two transversely opposing electrically-heated sealing jaws 62a, 62b. These sealing jaws respectively carry flat, presser plates 63a, 63b and are operated together between working and retracted positions. Lower edge jaws 66, 67 of the respective plates and jaws are slanted outwardly and downwardly to support and shape portions of side walls W1, W2 of the paper tube T in forming upper inclined panels P1, P1 of a box B1, Fig. 4. Resistance heater elements 66a, 66b are respectively provided in the sealing jaws 62a, 62b. The jaws are respectively carried by axially aligned and horizontal shafts 70a, 70b and may be operated by any suitable means such as plungers 71a, 71b of solenoids 72b. Two fingers 73 with rounded ends extend inwardly from jaw 62b toward the jak 62a for engaging and supporting portions of opposite sides W3, W4 of paper tube T where transverse seam S1 is formed by the cooperating sealing jaws 62a, 62b. The transverse sealing jaws 62a, 62b are adapted to be pulled downwardly when in engagement with the paper tube T having sealed the same to advance the finished box and paper tube T the length of one box. Any suitable mechanism may be used for carrying out this method step. The seam sealing bar 50 is preferably operated with the transverse sealing jaws 62a and 62b but will be retracted before the sealing jaws are retracted and given their downward movement. The vertical seam sealing bar 50 may also have been Worked with the opposing die fingers 56a, 56b.

Located a predetermined distance below the lower end of inner tube 22 is a movable horizontal platen 75. This platen has a square edge 76 which is presented to the rear side of the center of transverse seam S2 at the bottom of box B1. An opposing horizontal cutter blade 77 with cutting edge 79 is movably mounted at the front of the apparatus and moves rearwardly to cooperate with platen 75 in cutting seam S2 in half leaving a downwardly projecting sealed seam S2 at the bottom of box B1 and a similar upwardly projecting seam S2" at the top of previously formed box B2. The platen 75 and blade 77 may be operated by any suitable means but preferably in common with the sealing bar 50 and the transverse sealing jaws 62a, 62b. The platen 75 and knife blade 77 will be retracted with the sealing bar 50 prior to the downward pull of the transverse seam sealing jaws to advance the paper tube T. If desired, the boxes can be left in chain formation and severed by independent cutting mechanism at another location, before or after shipment.

The sealing bar 50, the side end indenting fingers 56a and 56b and the platen 75 and knife blade 77 can all be worked in common with the transverse sealing jaws 62a, 62b or with one another prior to their sealing operation but in all instances, the operation of all must be effected prior to the downward pull movement of the transverse sealing jaws. The filling of the boxes with the fluent material may be effected during or at the end of the downward pulling of the paper tube by the transverse, sealing jaws 62d and 62b or thereafter and upon the transverse seam having been made.

All elements will be operated in timed relationship With one another.

In FIG. 9, the steps are diagrammatically set forth, but it should be apparent that the steps I and II can be simultaneously performed and the step III thereafter.

FIGS. 5-8 show box B2 as made by the method and apparatus described above. This box B2 is rectangular in crosssection with opposing vertical walls W1, W2, and W3, W4. Top and bottom seams S2 and S2" are formed by part of vertical seal SL1 and horizontal seals SL2, SL2, SL3. It will be noted that end seals SL2 and SL2 are formed by parts of outer thermoplastic coating L1 fused to each other inside of folds F1, F1. Center seal SL3 is formed by parts of inner thermoplastic coating or layer L2 fused to each other. Inner seals SL3 and SL3" formed in outer fold portions F2, F2 are also formed by parts of coating or layer L2 fused to each other. Seal SL1 is formed by part of coating or layer L1 fused to part of coating or layer L2.

In FIGS. -13 is shown a box B2 which is similar to box B2 and is formed by the apparatus and method previously described, except that the fingers 56a, 56b are not used during the operating cycle and folds F1, F1 and F2, F2 are not formed. This produces outwandly-extending wings WG, WG' at ends of the seams SM2', SM2 of the box. The seams SM2' and SM2" are longer than the width of panels W1, W2 of the box. These wings facilitate the holding and handling of the box. The construction of box B2 will generally be preferred since the folded-in ends of the end sea-m corners of the tube are then coplanar with the narrow sides W3, W4 of the box.

The invention described thus provides a unique packaging method in which boxes are formed, filled, sealed and separated in a novel manner. The paper B may be preprinted prior to coating with thermoplastic layers L1, L2. This printing will appear on the exposed sides of the boxes. No pre-creasing, pre-scoring or pre-cutting of paper web has been necessary in carrying out this method. This has all been done with plain paper.

While this method involves intermittent feed of web W it is continuous since at all times the web is being fed and the paper tube T is being formed and filled, and the upper box B1 is being sealed, closed, and filled and the lower box is being out free from box B1.

While one apparatus has been shown to carry out this packaging method, it will be understood that the apparatus can take various forms and that the propelling means for the paper tube can be effected in any manner, other than the jaws 62a and 62b while forming and gripping the transverse seam S1 pulling down the tube with it before release and then returning for the next transverse seam forming operation.

It should be apparent that boxes of firm paper sheet taken from a roll will have been prepared thereby from plain paper sheet stock without any preparatory creasing, folding or scoring operation upon the paper stock and handled more or less in the manner as thin sheet material could have handled. or shaped, the final product or box at the same time being a self-supporting rigid paper box.

While there has been illustrated and described the preferred embodiments of the invention, it is to be understood that the inventionis not to be limited to the precise constructions herein disclosed and that various changes and modifications may be made within the scope of the invention as defined by the appended claim.

Having thus shown and described the invention, what is claimed as new is:

1. A packaging method for boxes made from a continuous web consisting of a foldable unscore-d heavy weight paper coated on opposite sides with thermally fusible plastic material, said method. including a cyclicallyrepeated method of two successive steps, the first step consisting of simultaneously sealing overlapped vertical edge portions of opposite sides of the paper web to form a vertically extending closed rectangular paper tube, indenting portions oftwo opposed small side walls of said tube to form reentrant folds, and cutting free from said tube a previously formed, sealed and filled box, the second step consisting of simultaneously transversely sealing the top of a newly formed filled box and the bottom end of said tube, advancing the newly filled box to locate the transverse seal at a cutting position, and filling a lower end portion of said paper tube with fluent material.

References Cited UNITED STATES PATENTS 3,048,951 8/1962 Olr 53--28 3,263,391 8/1966 Wallsn 53-28 FOREIGN PATENTS 835,306 5/1960 Great Britain.

TRAVIS s. MCGEHEE, Primary Examiner.

E. F. DESMOND, Assistant Examiner. 

